Operating Instruction BA 168 EN - Edition 11/16

Transcription

1 Bauer Gear Motor GmbH Eberhard-Bauer-Straße Esslingen am Neckar Operating Instruction BA 168 EN - Edition 11/16 Translation Title Page EU Declaration of Conformity 2-3 Safety information for the operation of geared motors 4-5 Geared motors with three phase cage rotors 6-13 Lubricants Lubrication quantity series BG 17 Lubrication quantity for BG20-01R 18 Lubrication quantity series BF 19 Lubrication quantity series BK 20 Lubrication quantity series BS 21 Lubrication quantity series BM 22 Lubrication quantity for gear design with free running input shaft 23 Lubrication quantity for gear design with integral motor 24 Lubrication quantity coupling lantern 25 Lubrication quantity for pre-stage 26 Lubrication quantity for intermediate gear 27 Brakes Spring-loaded brakes with direct current solenoid relase Models E003B und E004B Spring-loaded brakes with DC solenoid release Models E../Z..008B, Z..015B, E../Z..075B, Z..100B, EH(X)027A EH(X)400A Brake connection: special rectifier ESG 1.460A Brake connection: DC voltage supply 50 Brake connection: special rectifier MSG...I Brake connection: special rectifier MSG...U 53 Brake connection: spandard rectifier SG 3.575A Rectifier on motor terminal block or cage clamp 58 Manual release spring loaded brake with DC solenoid model E003B und E004B Manual release spring loaded brake with DC solenoid model E../Z..008B, Z..015B, E../Z..075B, Z..100B Gearmotors Gear units designed with torque arms and rubber buffers for series BF 63 Gear units designed with torque arms and rubber buffers for series BK 64 Gear units designed with torque arms and rubber buffers for series BS 65 Geared motors with built-on backstop Assembly of standard motor with C-Adapter (IEC and NEMA) 71 Assembly and disassembly of the shrink-disc 72 Information on the storage of geared motors with cage rotors These documents must be kept with the unit. Further documentation can be found under

2 EU Declaration of Conformity Low Voltage Directive 2014/35/EU Ecodesign Directive 2009/125/EC B Version: 04/2016 EE-ge File: 2016_KonfErkl_NSR_ErP_ASM_B_010_0800_02_EN Bauer Gear Motor GmbH Postfach Esslingen Eberhard-Bauer-Str Esslingen Telephone: +49 (0) Fax: +49 (0) info@bauergears.com Website: Bauer Gear Motor GmbH Eberhard-Bauer-Str. 37, Esslingen declares on its sole responsibility the conformity of the following products: Asynchronous motors from the series D..04, D..05, D..06, D..07; D..08, D..09, D..11, D..13, D..16, D..18, D..20, D..22, D..25, D..28 E..04, E..05, E..06, E..07, E..08, E..09 where necessary, in conjunction with gears from the series: BG.., BF.., BK.., BS.., BM.. with the requirements of the European Directives DIRECTIVE 2014/35/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 26 February 2014 on the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits. Published on 29 March 2014 in the Official Journal of the EU L96/357. DIRECTIVE 2009/125/EC 1) OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 21 October 2009 establishing a framework for the setting of ecodesign requirements for energy-related products. Published on 31 October 2009 in the Official Journal of the EU L285/10. 1) Where the products fall under the scope of this Directive, the requirements of COMMISSION REGULATION (EC) No 640/ Establishing electric motor ecodesign requirements - of 22 July 2009 and 6 January 2014 are met. Additional product labels HE; PE (IE2: IE3 according to EN ) The object of declaration described above is in conformity with the Union s relevant harmonization legislation, proven by the compliance with the following harmonised standards: EN : Cor.:2010 EN :2014 EN :2001/A1:2007 EN :2007/A1:2014 EN :2014 EN 60529:1991/A1:2000/A2:2013 Additional information: Three-phase motors do not fall under the scope of the EMC Directive, since as passive elements they are neither susceptible for the purpose of interference resistance, nor do they affect the environment by emitting high-frequency interference. Operation of these motors in the case of power supply through switch-mode supplies (converter) and the associated EMCrelevant aspects are the responsibility of the user of this PDS (Power Drive System). The instructions in the converter s product documentation must be observed. The installer is responsible for the final EMC properties of the device, system or installation. Esslingen 20. April 2016 Bauer Gear Motor GmbH K.P. Simon (Managing Director and President) P. Cagan (Quality Director) This certificate does not contain any guarantee of features in terms of product liability. The technical documentation is produced and administered by Bauer Gear Motor GmbH. Ihre treibende Kraft - Your driving power 2 An Altra Industrial Motion Company

3 EU Declaration of Conformity Low Voltage Directive 2014/35/EU B Version: 04/2016 EE-ge File: 2016_KonfErkl_NSR_PMSM_B_010_0800_03_EN Bauer Gear Motor GmbH Postfach Esslingen (Germany) Eberhard-Bauer-Str Esslingen (Germany) Telephone: +49 (0) Fax: +49 (0) info@bauergears.com Website: Bauer Gear Motor GmbH Eberhard-Bauer-Str. 37, Esslingen (Germany) declares on its sole responsibility the conformity of the following products: Permanent magnet three-phase synchronous motors in the series S..04, S..05, S..06, S..07; S..08, S..09, S..11, S..13, S..16, S..18 where necessary, in conjunction with gears from the series: BG.., BF.., BK.., BS.., BM.. with the requirements of the European Directives DIRECTIVE 2014/35/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 26 February 2014 on the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits. Published on 29 March 2014 in the Official Journal of the EU L96/357 The object of declaration described above is in conformity with the Union s relevant harmonisation legislation, proven by the compliance with the following harmonised standards: EN :2010/AC:2010 EN :2001/A1:2007 EN :2007/A1:2014 EN 60529:1991/A1:2000/A2:2013 Additional information: Three-phase motors do not fall under the scope of the EMC Directive, since as passive elements they are neither susceptible for the purpose of interference resistance, nor do they affect the environment by emitting high-frequency interference. Operation of these motors in the case of power supply through switch-mode supplies (converter) and the associated EMCrelevant aspects are the responsibility of the user of this PDS (Power Drive System). The instructions in the converter s product documentation must be observed. The installer is responsible for the final EMC properties of the device, system or installation. Esslingen, 20 April 2016 Bauer Gear Motor GmbH K.P. Simon (Managing Director and President) P. Cagan (Quality Director) This certificate does not contain any guarantee of features in terms of product liability. The technical documentation is produced and administered by Bauer Gear Motor GmbH. Ihre treibende Kraft - Your driving power An Altra Industrial Motion Company 3

4 Safety information for the operation of geared motors (in accordance with the Low Voltage Directive 2014/35/EU) General This safety information applies in addition to the relevant product-specific operating instructions and for safety reasons must be taken into particular consideration in every case. This safety information is intended to protect persons and objects from injury and hazards which can arise from improper use, incorrect operation, inadequate maintenance or other incorrect handling of electric drive units in industrial installations. Low-voltage machines have rotating parts and may have parts that are live, even when the machine is at rest, and surfaces that may become hot in operation. Warning signs and information signs on the machine are to be observed without exception. Details may be found in our detailed operating instructions. They are provided with the machine when it is supplied and can be requested separately as required by stating the motor model. 1 Personnel All necessary work on electric drive units, in particular also planning work, transport, assembly, installation, commissioning, maintenance, repair, may only be performed by adequately qualified personnel (e.g. electrical engineers as specified in draft EN /DIN VDE 0105), who have the operating instructions provided and other product documentation available during any corresponding work and who are obliged to abide by the instructions contained therein. This work is to be monitored by a specialist supervisor. Qualified personnel are persons who are authorised due to training, experience and instruction as well as their knowledge of relevant standards, rules, accident prevention regulations and operating conditions by the person responsible for the safety of the installation to perform the activities required in each case and who are able to recognise and avoid possible hazard. Knowledge of first-aid measures and of the available lifesaving equipment is also required. Non-qualified personnel shall be forbidden to work on the geared motors. 2 Intended use taking into account the relevant technical regulations These machines are intended for commercial installations, unless otherwise expressly agreed. They comply with the standards of the series EN 60034/DIN VDE Use in a potentially explosive atmosphere is forbidden, if not expressly intended for this purpose (refer to additional information). If in a special case --use in non-commercial installations-- Increased safety precautions are required (e.g. protection against access by children s fingers), these conditions are to be ensured when setting up the installation. The machines are designed for ambient temperatures between -20 C to +40 C as well as for installation heights up to 1000 m above sea level. Data for Units designed for differing ambient temperarures on the rating plate. Any deviations found on the rating plate must be taken into consideration. The conditions at the place of work must correspond to all rating plate data. Low-voltage machines are components for installation in machines in the sense of the Machinery Directive 2006/42/EC. It is forbidden to use the machine until conformity of the final product with this directive is established (consult EN ). 3 Transportation, storage Only the attachment points provided by the factory may be used for transporting and installing the geared motors. When the electric drive units are being transported, the eye bolts -- where provided in the design-- must be firmly tightened down their bearing surface. They may be used only for transporting the drive unit and not for lifting both the drive unit and the driven machine. Damage sustained after delivery must be reported to the haulage company immediately. Commissioning may have to be suspended. If drive units are to be stored, ensure a dry, dust free and low vibration (veff < 0,2 mm/s) environment (damage sustained during storage). The life of the lubricants and seals is reduced with longer storage times. There is a risk of fracture at very low temperatures (under approximately - 20 C). If the transport eye bolts are replaced, drop forged eye bolts as specified in DIN 580 are to be used. 4 Mounting arrangement, assembly The drive unit is to be fastened by its flange or foot if an IM.. mounting arrangement is intended. Gear units with hollow shafts are to be attached on the driven shaft using the means provided. Caution! Depending on the reduction ratio, geared motors develop substantially higher torques and forces than highspeed motors of similar power. Mounts, substructure and torque restraint are to be rated for the high forces to be anticipated during operation and secured sufficiently against loosening. The output shaft(s) and any second motor shaft extension present as well as the transmission elements mounted on it (couplings, chain wheels etc.) are to be covered so that they cannot be touched. 5 Connection All work shall only be carried out by qualified technical personnel on a stationary machine which has been protected against re-starting. This applies also to auxiliary circuits (e.g. stationary heating). Remove any transportation blocks before start-up. 4

5 Safety information for the operation of geared motors Check to ensure safe isolation from the supply! The terminal box may only be opened once it has been ensured that the power is switched off. The information on voltage and frequency on the rating plate must correspond with the mains voltage under observance of the terminal circuit. Exceeding the tolerances as in EN / DIN VDE 0530, i.e. voltages ± 5 %, frequency ± 2 %, cam form, symmetry, increases heating and reduces service life. Accompanying connection diagrams, particularly for special equipment (e.g. pole-changing, thermistor protection etc.), are to be observed. Type and cross-section of the main conductors as well the protective conductors and any potential equalization which may become necessary must correspond to the general and local installation regulations. With switching duty, the starting current is to be taken into account. The drive unit is to be protected against overloading and in dangerous situations against automatic restarting due to inadvertent starting. The terminal box is to be locked again to protect against contact with live components. 6 Commissioning Before commissioning, protective films are to be removed, the mechanical connection to the driven machine disconnected as far as possible and the direction of rotation examined in the no-load state. Feather keys are to be removed or secured in such a way that they cannot be ejected as this is done. Ensure that the current draw in the loaded condition does not exceed the rated current indicated on the rating plate for any length of time. Observe the drive unit after first commissioning for at least one hour for any unusual heat or noise. 7 Operation With certain layouts (e.g. unventilated machines), relatively high temperatures can occur on the motor frame, which are however within the limits specified in the standard. If these drive units are located in a place where they are subject to intensive contact, measures must be taken by the installer or operator to provide protective shielding. 8 Spring-loaded brakes Spring-loaded brakes are safety brakes which continue to work in the event of power failure or usual wear. With a spring loaded brake with manual release option, the operator must ensure that the manual release of the brake cannot be actuated accidentally. If the operator removes the manual release lever for this purpose, then, in the case that the brake is built in under the fan cowl, he must allow for suitable contact protection at the emerging opening of the sheet metal fan cowl. Since other components could also fail, suitable safety precautions are to be taken to avoid any injury to persons or damage to objects cause by un-braked operation. 9 Maintenance In order to prevent breakdowns, danger and damage, the drive units must be examined at regular intervals depending on the operating conditions. The lubrication intervals for bearings and gear units specified in the respective operating instructions are to be observed. Worn or damaged parts are to be replaced using original spare parts or standard parts. In the event of heavy dust accumulation, clean airways regularly. For all inspection and maintenance work, observe Section 5 and the information provided in the detailed operating instructions. 10 Operating instructions For reasons of clarity, the operating instructions and safety information do not contain all information relating to all geared motors types and cannot take into account every conceivable case of installation, operation or maintenance. The information is essentially limited to that which is required for qualified personnel in normal working situations. Any unclear points can be clarified by contacting Bauer. 11 Faults Changes in relation to normal operation, such as higher temperatures, vibrations, noises etc. tend to indicate that the function is impaired. To avoid faults which could lead directly or indirectly to injury to persons or damage to property, the maintenance staff responsible must be informed. If in any doubt, the geared motors are to be switched off immediately. 12 Electromagnetic compatibility The operation of the low-voltage machine in its intended application must meet the protection requirements of the EMC (electromagnetic compatibility) Directive 2014/30/EU. Correct installation (e.g. screened cables) is the responsibility of the system s installers. Precise information can be taken from the operation instructions. For systems with frequency inverters and rectifiers, the manufacturer s electromagnetic compatibility information is also to be taken into consideration. The electromagnetic compatibility directive in accordance with EN and EN is complied with given proper use and installation of BAUER geared motors. This is also true in combination with frequency inverters and rectifiers. The additional information provided in the operation instructions is to be taken into consideration when using the motors in the residential, commercial and trade sectors, as well as in small businesses in accordance with EN and EN Warranty and liability The warranty obligations of Bauer arise out of the relevant supply contract, which is neither expanded nor restricted by this safety information or other instructions. This safety information is to be kept in a safe place. 5

6 Geared motors with three phase cage rotors In the standard version the drives are designed for an ambient temperature range of 20 C to +40 C and for installation elevations up to 1000 m above sea level; differing conditions are marked on the nameplate. Exposure to dirt, moisture and the usual outdoor conditions may not exceed the level corresponding to the IP protection rating. The air inlet and outlet must be kept free of obstruction (for example, due to an acoustic cover). Motor sizes Minimum clearance a at air inlet Up to D mm D.. 18 to D mm D.. 25 and above 125 mm General Notes Disclaimer 1 Geared motors in degree of protection IP65 2 Geared motors in degree of protection IP54 The operating instructions are an intergral element of the product and must be available in a readable form at all times. Employees responsible for the plant and operations together with all who have to work with the unit must have read and understood the operating instructions completely. Observation of the operating instructions is a prerequisite for the safe use and the attainability of the product performance of the geared motor. Bauer does not accept liability for personal, material or economical damages caused by non-observation of the operating instructions. Liability for defects are excluded in such cases. (Motor models D/E06... to D.28...) complying with EN and IEC 34-5/529 are totally enclosed and dust-tight as well as hose proof. For outdoor installation, the geared motor must be coated with several layers of durable paint to protect against corrosion. The condition of the paint must be checked and repaired at regular intervals, depending on ambient influences. The paint finish must be compatible with the other components. Paints with a synthetic resin base have proved well suited to this purpose. (Motor models D/E04... and D/E05...) complying with EN 60034, part 5 and IEC 34-5 are protected against dust and occasional splashing water. Installation outdoors or in wet areas is not permissible without special protective measures. 6

7 Geared motors with three phase cage rotors 3 Mounting arrangement It is recommended that drinking water, food, textiles etc. beneath the geared motor be covered. The drive unit should be installed as free from vibration as possible. Special instructions are to be observed in installation locations with abnormal operating conditions (e.g. prolonged exposure to dripping water, high ambient temperatures above 40 C, explosion hazards). The fresh air intake must not be restricted by unsuitable installation or by fouling. Flexible couplings with zero play, if possible, are recommended for direct power transmission from the gear unit to the driven machine and commercially available slip clutches are recommended if there is a risk of blocking. Care must be taken when fitting transmission elements onto the output shaft of the gear unit, which is finished to ISO k 6 or m 6, and the tapped end hole intended for this purpose according to DIN 332 should be used if possible. Warming the machine part to be fitted onto the shaft to approximately 100 C has proved to be advantageous. The bore must be dimensioned in accordance with following table and must thus exhibit the following tolerances: Nominal size of bore (in mm) over 6 to 10 0 to + 15 over 10 to 18 0 to + 18 over 18 to 30 0 to + 21 over 30 to 50 0 to + 25 over 50 to 80 0 to + 30 over 80 to to + 40 k 6 or m 6 output shaft Bore H7 with tolerances (in 1 / 1000 mm) Where the gear units have a hollow shaft and keyway for high profile feather keys as specified in DIN 6885, Part 1 and hollow shaft for shrink-disc connection, the shafts intended to form the counterpart must be dimensioned to ISO h 6. They must, therefore, exhibit the following tolerances: Shaft diameter (in mm) Nominal allowance (in 1 / 1000 mm) over 18 to 30 0 to - 13 over 30 to 50 0 to - 16 over 50 to 80 0 to - 19 over 80 to to - 22 over 120 to to

8 Geared motors with three phase cage rotors In all cases, particular care shall be taken to ensure that any burring, swarf etc. is carefully removed before assembly. The keyways should be lightly greased to prevent seizing. Hollow shafts to be fitted with shrink-disc connections must not be greased. The following installation instructions are to be noted here. The eye bolt is to be retightened firmly if it has worked loose during transportation. 4 Electrical connection When connecting the motor, take note of the rating plate information and the connection diagram as well as the relevant safety regulations and rules for the prevention of accidents. Unless a special design is concerned, the rating data refer to ± 5 % voltage tolerance, -20 to 40 C ambient temperature and altitudes up to 1000 m above sea level. Small motors can be connected directly (the regulations of the local electricity supply companies are to observed). The permissible switching frequency depends on the design of the motors, the load torque and the mass moment of inertia. The direction of rotation of single phase motors may generally only be changed after the motor has stopped and in accordance with the following diagram: Direction of rotation I Direction of rotation II 8

9 Geared motors with three phase cage rotors Unless otherwise stated, the three phase motor is connected for the higher of the two rated voltages specified. The motor may have to be connected from star to delta at the terminal board, if necessary, to ensure that it complies with the mains voltage. Specially designed motors (e.g. for two rated voltages in the ratio 1:2 or with pole-changing windings) are to be connected in accordance with the relevant circuit diagram. Two mains leads must be swapped in the event of incorrect direction of rotation. When closing the terminal box, particular attention must be given to obtaining a perfect seal. With motors in sizes D/E 04 to D/E 09 with moulded terminal boxes, two connection openings each on side A and C are possible. The cable entry openings required depending on the installation position should carefully pierced with a suitable tool. Take care not to damage the terminal board. Two lock nuts and seals are provided in the terminal box for the cable glands (metric). Plugs must be screwed into unused cable entry holes. The maximum spanner opening for the cable glands of the D04 is 24 mm and of the D05 to D09 is 29 mm. To guarantee electromagnetic compatibility (EMC) as defined in EMC Directive 2014/30/EU, all signal lines must use shielded cables. The cable sheath is to be earthed at both ends. The frequency inverter operating instructions will indicate whether a shielded cable is necessary for the motor supply line. A shielded motor cable is not required when connecting to the low-voltage network or to a frequency inverter with an output filter. Signal cables and power cables should not be laid parallel over long distances. 5 Overload protection A motor protection switch must be used to protect the winding against overloading and against the consequences of operating on only 2 mains leads (e.g. when only one fuse blows or in the event of a wire breakage) Example Motor winding for 230/400 V; Rated currents Setting of the motor protection switch at Connection for 230 V (delta): Connection for 400 V (star): 5.7/3.3 A 5.7 A 3.3 A 9

10 Geared motors with three phase cage rotors The overcurrent relay of the motor protection switch is to be set to the correct rated current intensity for the rated voltage concerned (see rating plate).take note of the relevant circuit diagram for motors with thermally activated winding protection (e.g. thermostats or thermistors). Automatic restarting after the winding has cooled must be avoided in most applications. The output of the motors is normally adequately rated, particularly in connection with four and multistage gear units. The rated current does not represent a measure of gear unit utilization in these cases and cannot be used as overload protection for the gear unit. In some cases, the way in which the driven machine is loaded can exclude any overloading as a matter of course. In other cases it is prudent to protect the gear unit by mechanical means (e.g. slip clutch, sliding hub etc.). The maximum permissible limit torque M 2 in continuous running duty specified on the rating plate is decisive here. Permanent-magnet synchronous motor (PMSM) The rotors on the PMSM machines are fitted with embedded permanent magnets. Caution: The magnetic field which is created may be harmful to health. For this reason, it is imperative to observe the accident prevention regulations of the respective country in workplaces where people are exposed to magnetic fields. In Germany, the accident prevention regulations BVG B11 (VBG25) Electromagnetic Fields must be observed. Please note that additional electromagnetic fields occur in operation. Warning: Magnetic fields emanating from the permanent magnets exert a very strong pull on magnetisable materials. Dismantlement of the motor must therefore only be carried out with special tools and auxiliary equipment. Once engine components, tools or other magnetisable materials are attracted to the rotor, it takes great effort to separate them again. In the event of dismantlement, the rotor must be removed in a guided and insulated manner. Caution: Hazard: The removed rotor must be protected from contamination such as metal shavings. Before reinsertion, the rotor must be thoroughly cleaned. The attraction of other objects may lead to severe bruising and injuries from attracted tools, such as screwdrivers, wrenches etc. 10

11 Geared motors with three phase cage rotors Commissioning Caution: Permanent-magnet synchronous motors can only be operated with a frequency converter. Direct connection to the mains is not possible. The motor data listed on the nameplate for the motor parameterisation must be used for commissioning. The values of the torque limit, limiting currents and limit speed on the nameplate must be observed. Caution: Exceeding these limit values may lead to motor damage as a result of heating, centrifugal force and demagnetisation of the permanent magnets, to gear damage resulting from overstressing and to system damage. In the event of application-related overloading, Bauer Gear Motor must be consulted. In generator operation, a PMSM works like a dynamo and generates tensioning on the open motor clamps through the movement of the rotor shaft or the drive components. Warning: Electric shock with slight personal injuries as a result of generator operation at the open motor clamps. Lubricant changes The gear units are supplied with lubricant ready for operation. In normal operating conditions and with a lubricant temperature of approximately 80 C, the oil should be replaced after approximately operating hours when using CLP 220, or after operating hours when using PGLP 220/PGLP 460. The lubrication interval must be reduced at higher temperatures (halve it for each 10 K increase in the lubricant temperature). The lubricant must be changed after 2 or 3 years at the latest whatever the operating hours. The medium and larger gear units have filling plugs and drain plugs. In the standard designs, these make it possible to change the lubricant without disassembly. With smaller gear units, the interior is accessed by unscrewing the connecting bolts. Alignment pins and centrings secure the precise assembly. Worm-gear units are sliding gear units whose tooth flanks, contrary to rolled gear units, only become smooth once run in. They should therefore initially be run in under partial loading (about 2 / 3 of the rated load) until the full load capacity of the flanks and the optimal efficiency is achieved. After approximately 200 operating hours, the lubricant should be changed and the gear unit enclosure thoroughly flushed, so that the minimal, but inevitable amount of material removed by smoothing abrasion is cleared. 11

12 Geared motors with three phase cage rotors It is also necessary to flush the gear unit enclosure if the lubricant grade or lubricant type is changed. If the motor is only used briefly it is sufficient to drain off the original oil and use the original lubricant type to refill the maximum possible amount for the gear unit as defined in the lubricant volume table. Then operate the drive unit briefly under no load, drain this oil off again and refill with the new lubricant as defined on the rating plate. In special cases, refill up to the oil level mark. If necessary, drain off the original lubricant and flush out the gear unit with petroleum until all traces have been washed out. Then perform the procedure described above for short-term operation twice before filling with the specified volume of new lubricant in accordance with the rating plate, in special cases up to the oil level mark. It is advisable to inspect and if necessary replace the wear parts (bearings and seals) when changing the lubricant. Lubricant grade Oils CLP 220, PGLP 220 and PGLP 460 complying with DIN and DIN are suitable for lubricating the gear unit, or in special cases use soft flow grease GLP 00f with good EP properties. The lubricant must permit low-friction, virtually wear-free continuous operation. The damage load level on the FZG test as specified in DIN shall be in excess of load level 12, and the specific wear below 0.27 mg/kwh. The lubricant should not foam, should protect against corrosion and should not attack the interior paint, the rolling contact bearings, gearwheels and seals. Lubricants of different types may not be mixed, as otherwise the lubrication characteristics may be impaired. A long service life is only ensured by the use of a lubricant listed below or which is demonstrably equivalent. Storage Should geared motors need to be stored for a longer period of time before installation, please observe the chapter Information on the storage of geared motors with cage rotors Wear-protecting EP gear lubricant oils as listed in the lubricant table below have proved particularly suitable. 12

13 Geared motors with three phase cage rotors Lubricant type Mineral Oil Synthetic Oil USDA H1 Oil ISO VG 220 ISO VG 68 ISO VG 220 ISO VG 460 ISO VG 220 Disposal No. ASN ASN ASN ASN ASN ASN Lubricant Manufacturer Standard oil for gearboxes in the series BF06-BF90 BG04-BG100 BK60-BK90 Low temperature oil for gearboxes in the series BF06-BF90 BG04-BG100 BK06-BK90 BM09-BM40 BS02-BS40 Standard oil for gearboxes in the series BS02-BS10 BK06-BK10 BM09-BM40 High temperature oil for gearboxes in the series BS02-BS10 BK06-BK10 BF06-BF90 BG04-BG100 BK60-BK90 BM09-BM10 Standard oil for gearboxes in the series BS20-BS40 BK17-BK50 BM20-BM40 High temperature oil for gearboxes BS20-BS40 BK17-BK50 BM20-BM40 AGIP BLASIA 220 BLASIA S 220 BLASIA S 460 Food and Beverage Industry Oil for gearboxes in the series BF06-BF90 BG04-BG100 BK06-BK90 BM09-BM40 BS02-BS40 BECHEM RHUS STAROIL G 220 BERUSYNTH EP 68 BERUSYNTH EP 220 BERUSYNTH EP 460 BERUSYNTH EP 220 H1 CASTROL ALPHA EP 220 ALPHA SP 220 ALPHA BMB 220 OPTIGEAR BM 220 OPTIGEAR EP 220 OPTIGEAR 1100/220 Alphasyn T68 ALPHASYN PG 220 OPTIGEAR 800/220 OPTIGEAR 1300/220 ALPHASYN GS 220 ALPHASYN PG 460 OPTIGEAR 800/460 OPTIGEAR 1300/460 ALPHASYN GS 460 OPTILEB GT 220 (CLP-HC) OPTILEB GT 1800/220 (CLP-PG) CHEVRON GEARTEX EP-A SAE 85W-90 Meropa 220 SYNLUBE WS 68 SYNLUBE WS 220 SYNLUBE WS 460 Chevron lubricating oils FM 220 (USA) FUCHS RENOLIN CLP 220 RENOLIN CLPF 220 SUPER RENOLIN CLPF 220 PLUS RENOLIN UNISYN CLP 68 RENOLIN PG 68 RENOLIN PG 220 RENOLIN PG 460 CASSIDA FLUID GL 220 KLÜBER KLÜBEROIL GEM N KLÜBER- SYNTH GH6-80 KLÜBERSYNTH GH6-220 KLÜBERSYNTH GH KLÜBEROIL 4UH1-220 N KLÜBERSYNTH UH MOBIL MOBILGEAR 600 XP 220 MOBIL SHC 626 MOBIL SHC CIBUS 220 OEST Gearol C-LP 220 SHELL OMALA S2 GX220 OMALA S4 WE 220 OMALA S4 WE 460 TOTAL CARTER EP 220 CARTER XEP 220 CARTER SY 220 CARTER SY 460 NEVASTANE SL220 NEVASTANE EP 220 NEVASTANE SY 220 WINTERSHALL SRS ERSOLAN 220 Attention: Synthetic gear oils with a polyglycol base (e.g. PGLP etc) must be kept separate from mineral oils and disposed of as special waste. As long as the ambient temperature does not fall below -20 C, ISO viscosity grade VG 220 (SAE 90) is recommended in accordance with the international definition of viscosity grades at 40 C in accordance with ISO 3448 and DIN 51519, and AGMA 5 EP in North America. 13

14 Geared motors with three phase cage rotors For lower ambient temperatures, oils of a lower nominal viscosity, with correspondingly better starting characteristics should be used, such as PGLP with a nominal viscosity of VG 68 (SAE 80) or AGMA 2 EP. These grades may also be required at temperatures around the freezing point if the drive unit s breakaway torque has been reduced with a view to achieving soft starting or if the motor has a relatively low power output. Lubricant volume Disposal The recommended lubricant quantity for the particular style is indicated on the rating plate of the motor (symbol ). When filling, make certain that the upper gear unit components, depending upon the installation position, are also well lubricated. The oil level mark should be taken into consideration in special cases. Information about the lubricant volume required for other styles construction can be obtained from the works. The metallic parts of the gear unit and the geared motor can be disposed of as scrap, segregated into steel, iron, aluminium and copper. The lubricants used are to be disposed of as waste oil, and the synthetic oils are to disposed of as special waste. Information on this can be found on the lubrication chart or the rating plate. Bearing lubrication Gearbox assemblies Gearbox bearings are usually open bearings. Open bearings in standard BAUER gearboxes are lubricated together with the gearing lubrication. Their maintenance therefore takes place as a part of the routine gearbox lubrication change. The bearings in special designs (Ex) can be in encapsulated design and equipped with their own grease reservoirs. In this case, the grease lubrication is renewed by changing the bearings themselves in the course of a regular gearbox lubrication change. Cleaning and re-greasing the bearings is not recommended due to the risk of impurifying the lubrication. Input assemblies Input assemblies of BAUER geared motors with integrated motors, including the gearbox size 80, the BF90 gearbox, the BG100 with all combinable motors, and the BG90 and BK90 gearboxes, up to and including D18, as well as gearbox sizes 10 to 100 with pre-stage with free running input shaft (-SN) for the gearbox sizes 06 to 70 and 10 to 100 with pre-stage for assembly with standard motors in sizes up to and including IEC180 or NEMA286 include factory-installed greased encapsulated bearings. 14

15 Geared motors with three phase cage rotors When operated at an input speed of 1500 rpm, a grease change is required after 10,000 hours of operation. In specific cases a maximum allowable input rpm of 3600 is allowable. If the input rpm is doubled, the grease change interval is halved. If the gearbox has encapsulated bearings in the input components, the grease change takes place by replacing the bearings while maintaining/inspecting the radial shaft seals. Cleaning and re-greasing the bearings is not recommended due to the risk of impurifying the lubrication.. Input assemblies of BAUER geared motors with integrated motors, including the BG90 and BK90 gearboxes up to and including D20, not for pre-stage with free running input shaft (-SN) for gearbox sizes 80 to 90 For assembly with standard motors in sizes as from and including IEC200 or NEMA324 are, in contrast to the encapsulated bearings described above, equipped with open, regreasable input bearings, an individual lubrication point or nipple is installed for each regreasable bearing. The maximum speed is 1800 rpm. The grease change interval is 2500 hours of operation however, a maximum of 6 months. The grease filling in the bearing is to be renewed after every 800 hours of operation by topping up with fresh grease. The entire grease filling is to be replaced after two grease top-ups at the latest. Approx. 40 g of additional grease is required to top up free running input shaft assemblies (-SN) and standard motor installation and three times as much (120 g) being required for a complete grease change. For integrated motor assemblies, 60 g of grease is required to top up and 180 g for a complete grease change. The topping up or exchange of the grease filling should be performed while the motor shaft is rotating in order to effect an optimal distribution of the grease in the bearing. When removing the grease, excess and used-up grease is to be removed from the grease discharge chamber. KLÜBER PETAMO GHY 133 N grease is to be used as lubricant. The grease type for encapsulated and regreasable bearings may vary from the standard for special-purposes lubrication (food-compatible, biodegradable, etc.). Ask the geared motor manufacturer about the correct lubrication for specific special applications. 15

16 Geared motors with three phase cage rotors Operating problems: Gear unit Failure Possible causes Remedy Oil leakage at: Shaft seal defective Change shaft sealing output shaft sealing motor shaft sealing Gearbox cover Motor flange Excess pressure in gear unit Excess pressure function check breather valve Contact Bauer Service Gear box output shaft does not turn although motor is switched on. Interruption of movement chain Contact Bauer Service Operating problems: Motor Failure Possible causes Remedy Output shaft is turning in the wrong wrong Motor connection direction Motor gets too hot Brake failure Bad ventilation of the motor Motor runs against a closed brake Brake is not lifting Friction partner worn out Change 2 phases with each other Check ventilation system Clean surface of motor (packing of dust) Check brake function Contact Bauer Service Check brake lift voltage Change friction partner Contact Bauer Service 16

17 Lubricants Helical Geared Motors Lubrication quantity series BG Lubrication quantities for BG gear series Lubrication quantity in l Gearbox type BG04-BG100 (gear-housing with flange or foot) Flange (Code-2./Code-3./Code-4./Code-7.) Foot with clearance holes (Code-9.) Foot with threads (Code-6.) [Completely machined (Code -8.)] H4 H1 H2 H3 H5 H6 B5 V1 V3 BG04-BG100 (Gearbox housing) cast-on-foot with clearance holes (Code -1.) BG04 BG05 BG06 BG10 BG15 BG20 BG30 BG40 BG50 BG60 B3 B6 B7 B8 V5 V BG BG BG BG Attachment housing Gearbox housing The actual gearbox design can vary from the geometry shown. 17

18 Lubricants Lubrication quantity for BG20-01R Gear (Motors) Additional Dimension Sheets Lubricant quantities, BG20R Lubrication quantity in l Gear type H4 H1 H2 H3 V5 V6 BG20R The actual gearbox design can vary from the geometry shown. 18

19 Gear (Motors) Additional Dimension Sheets Lubricants Lubrication quantity series BF Lubrication quantities for BF gear series Lubrication quantity in l Gear type H1 H2 H3 H4 V1 V2 BF BF BF BF BF BF BF BF BF BF The actual gearbox design can vary from the geometry shown. 19

20 Lubricants Lubrication quantity series BK Gear (Motors) Additional Dimension Sheets Lubrication quantities for BK gear series Lubrication quantity in l Gear box type H1 H2 H3 H4 V1 V2 BK BK BK BK BK BK BK BK BK BK BK The actual gearbox design can vary P-7117-BGM-EN-A5 from the geometry 11/16 shown.

21 Lubricants Gear (Motors) Additional Dimension Sheets Lubrication quantity series BS Lubrication quantities for BS gear series Lubrication quantity in l Gear type H1 H2 H3 H4 V1 V2 BS BS BS BS BS BS BS BS The actual gearbox design can vary from the geometry shown. 21

22 Lubricants Gear (Motors) Additional Dimension Sheets Lubrication quantity series BM Lubricant quantities, BM-series gears Lubrication quantity in l Gearbox type H1 H2 H3 H4 V1 V2 BM BM BM BM * BM30/S * on request BM30/S * BM * BM40/S * BM40/S * *: Lubrication quantity für BM30Z/BM40Z Caution: if * is shown the lubrication quantity of the pre-stage is filled into the main gear. 22 The actual gearbox design can vary from the geometry shown.

23 Lubricants Gear (Motors) Lubrication quantity for execution with integral motors Additional Dimension Sheets Lubrication quantity for gear design with integral motor BF BG H4 H4 B3/B5 H1 H2 H3 V1 V2 H1 H2 H3 V1 V3 B6 B7 B8 V5/H5 V6/H6 BK / BS H1 V1 V2 H2 H4 H3 Motor size D..04; E..04 D..05; E..05 D..06; E..06 D..07 D..08; S..08 D..09; S..09 not regreasable D..11; S..11 D..13 D..16 D..18 D..20; D..22 D..20; D..22 not regreasable Exception: BG90; BK90 only at BG90; BK90 regreasable lubricant to be used: KLÜBER Petamo GHY133N Amount of grease for regreasing: approx. 60g (--> BA..) Amount of grease for renewal: approx 180g (--> BA..) The actual design can vary from the geometry shown. 23

24 Lubricants Lubrication quantity for gear design with free running input shaft BF BG H4 H4 B3/B5 H1 H2 H3 V1 V2 H1 H2 H3 V1 V3 B6 B7 B8 V5/H5 V6/H6 BK und BS H1 V1 V2 H2 H4 H3 Gear type BK06-SN / BS06-SN BG10-BG10Z-SN BF10-BF10Z-SN BK10-BK10Z-SN BS10-BS10Z-SN BG20-BG20Z-SN BF20-BF20Z-SN BK20-BK20Z-SN BS20-BS20Z-SN BG30-BG30Z-SN BF30-BF30Z-SN BK30-BK30Z-SN BS30-BS30Z-SN BG40-BG40Z-SN BF40-BF40Z-SN BK40-BK40Z-SN BS40-BS40Z-SN BG50-BG50Z-SN BF50-BF50Z-SN BK50-BK50Z-SN Not regreasable BG60-BG60Z-SN BF60-BF60Z-SN BK60-BK60Z-SN BG70Z-SN BF70Z-SN BK70Z-SN BG80Z-SN BF80Z-SN BK80Z-SN BG90Z-SN BF90Z-SN BK90Z-SN BG100Z-SN BG70-SN BK70-SN BF70-SN BG80-SN BF80-SN BK80-SN BG90-SN BK90-SN BF90-SN BG100-SN regreasable lubricant to be used: KLÜBER Petamo GHY133N Amount of grease for regreasing: approx. 40g (--> BA..) Amount of grease for renewal: approx 120g (--> BA..) 24

25 Lubricants Gear (Motors) Lubrication quantity for execution with coupling - C Additional Dimension Sheets Lubrication quantity for coupling lantern BF BG H4 H4 B3/B5 H1 H2 H3 V1 V2 H1 H2 H3 V1 V3 B6 B7 B8 V5/H5 V6/H6 BK / BS H1 V1 V2 H2 H4 H3 Gear type BK06-C / BS06-C BG10-BG10Z-C BG20-BG20Z-C BF10-BF10Z-C BF20-BF20Z-C BK10-BK10Z-C BK20-BK20Z-C BS10-BS10Z-C BS20-BS20Z-C BG30-BG30Z-C BG40-BG40Z-C BF30-BF30Z-C BF40-BF40Z-C BK30-BK30Z-C BK40-BK40Z-C BS30-BS30Z-C BS40-BS40Z-C BG50-BG50Z-C BG60-BG60Z-C BF50-BF50Z-C BF60-BF60Z-C BK50-BK50Z-C BK60-BK60Z-C BG70-C BF70-C BK70-C BG100Z-C BK80-C BG90-BG90Z-C BG100-C BF90-C BK90-BK90Z-C BG70Z-C BG80Z-C BG80-C BF80-C BF70Z-C BK70Z-C BF80Z-C BK80Z-C BF90Z-C up to IEC180 or up to Nema284/286TC Not regreasable BG70-C BK70-C BF70-C BG80-C BK80-C BF80-C BG90-BG90Z-C BK90-BK90Z-C BF90-C BG100-C only from IEC200 up only from Nema324/326TC up regreasable lubricant to be used: KLÜBER Petamo GHY133N Amount of grease for regreasing: approx. 40g (--> BA..) Amount of grease for renewal: approx 120g (--> BA..) The actual design can vary from the geometry shown. 25

26 Lubricants Gear Lubrication (Motors) quantity for pre-stagelubricant quantities, pre-stage gears (Z) Additional Dimension Sheets Lubrication quantity in l BF BG H4 H1 H2 H3 V1 V2 H4 H1 H2 H3 V1 V3 B3/B5 B6 B7 B8 V5/H5 V6/H6 BK und BS H1 V1 V2 H2 H4 H3 Gear type BG10Z BK10Z BF10Z BS10Z BG20Z BK20Z BF20Z BS20Z BG30Z BK30Z BM30Z BF30Z BS30Z 0.2* BG40Z BK40Z BM40Z BF40Z BS40Z 0.32* BG50Z BK50Z BF50Z BG60Z BK60Z BF60Z BG70Z BK70Z BF70Z BF80Z BG80Z BK80Z BF90Z BG100Z BG90Z BK90Z *: The lubricant of the pre-stage for BM30Z/BM40Z is filled in the main gearbox. The actual gearbox design can vary from the geometry shown. 26

27 Lubricants Gear (Motors) Lubrication quantity for intermediate Libricant gear quantities, intermediate gears Additional Dimension Sheets Definition of the terminal box position Terminal box position for intermediate gear is similar to the main gearbox that means Main gearbox BG,BF terminal box pos. I -> intermediate gearbox terminal box pos. I Main gearbox BK,BS terminal box pos. II -> intermediate gearbox terminal box pos. II Lubrication quantity in liquid pint Mounting position of main gearbox BF BG BK und BS H4 H1 H2 H3 V1 V2 H4 H1 H2 H3 V1 V3 B3/B5 B6 B7 B8 V5/H5 V6/H6 H1 V1 V2 H2 H4 H3 Standard position of KLK mounting position H1,H2,H3, B5,V1,V3 for mounting with screwed resp. casted flange B5 H1 H2 H3 V1 V3 Type designation of double gearbox combination BG06G04 BS06G04 BK06G BG10G06 BF10G06 BK10G06 BS10G BG20G06 BK20G06 BF20G06 BS20G BG30G06 BK30G06 BF30G06 BS30G BG40G10 BF40G10 BK40G10 BS40G BG50G10 BF50G10 BK50G BG60G20 BF60G20 BK60G BG70G20 BF70G20 BK70G BG80G40 BF80G40 BK80G BG90G50 BF90G50 BK90G50 BG100G The actual gearbox design can vary from the geometry shown. 27

28 Brakes Spring-loaded brakes with direct current solenoid release Models E003B and E004B Safety information Connection, adjusting and maintenance work may only be carried out taking into account the safety information given on pages 4/5. Caution: Brakes are safety-relevant components; therefore, only qualified personnel with product-specific training may perform work on them. To find your nearest service partner, visit These spring loaded brakes are working brakes. The brakes perform frictional work in standard duty e.g. a braking function is performed. In addition to holding loads in the idle state, the spring-loaded brake slows rotating and linear moving masses, thus reducing unwanted overtravel distances and times. The brake is released electromagnetically. Under zero-load conditions, braking force is applied by spring pressure. Because braking is still effective even if an accidental power failure occurs, it can be considered a safety brake within the context of accident prevention regulations. During the braking process, the kinetic energy of the mass moments of inertia is converted into heat via the brake disc. The brake disc, which consists of high-quality, asbestos-free material, is highly resistant to wear and heat. A certain amount of wear is unavoidable, however. For this reason, the limit values specified in paragraph MAINTENANCE regarding the working capacity and the minimum lining thickness are to be strictly observed. Operating principle The operating principle is described in Figure 1. Brakes The brake disc (1) is pressed axially through the retaining plate (2) against the friction plate (4) by springs (3). Radial movement of the retaining plate is prevented by the fillister screws (5). The braking torque is transferred to the rotor via gear teeth connecting the brake disc and the carrier (6) fixed to the shaft. The braking torque and the number of springs can be changed in stages (see paragraph 6). Brake release Supplying the coil (7) with the correct DC voltage causes the retaining disc to be attracted by the magnetic field generated in the magnet housing (8) against the spring force. This relieves the brake disc and as a result allows the rotor to move freely. The increased air gap s L caused by the wear to the brake discs can be overcome thanks to the generous dimensioning of the electromagnets. No adjustment facility is hence provided. All brakes can be optionally fitted with either a latching or non-latching manual release, which may be used to release the brake manually e.g. in the event of a power failure. 28